Pack of a Personal Cleaning Product; Its Manufacture; and Its Use

ABSTRACT

A pack comprising a block of personal cleansing composition cast in a receptacle, wherein: 
     the personal cleansing composition is solid at an ambient temperature and liquid at an elevated temperature; 
     the personal cleansing composition is in direct contact with the receptacle; 
     the receptacle is resistant to the liquid form of the personal cleansing composition; and 
     the receptacle is configurable into a collapsed form to free the block.

This invention relates to a pack of a personal cleansing product, and to its manufacture, and its use.

An example of a personal cleansing product is a so-called “melt and pour” soap. This is a personal cleansing product which is solid at an ambient temperature, and liquid at an elevated temperature. When the composition is manufactured it is at an elevated temperature, and liquid. Following manufacture it is allowed to cool, and sets into blocks. The blocks are packed and transported to locations at which soap bars, to be sold to the general public, are made. There, the blocks are melted, additised if required (additives, where used, may, for example, include one or more of moisturisers, fragrances and colourants) and poured into small moulds to form the bars.

In this specification the term block is used to denote the intermediate product, which is sold to manufacturers of the bars which are to be sold to the public.

The blocks are substantially larger than the bars. To form a block, the liquid cleansing composition at an elevated temperature may be poured into a plastic bag, which solidifies into the form of the block. The plastic bag may be placed in a shape-stable receptacle, before or after filling, such that the cleansing composition generally adopts the shape of the receptacle. When the cleansing composition block is about to be re-melted to form the bars it must be separated from the bag. It is commonly found to be difficult to peel the film material of the bag away from the block. There are likely to be regions where the bag is wrinkled, such that the bag and the cleansing composition are inter-engaged with each other in a complicated way, rather than being in face-to-face contact. In regions where there is inter-engagement separation is particularly unlikely to be clean. It is common for solid cleansing composition to be left on the bag, or, more problematically, for pieces of plastic torn from the bag to be left on the said cleansing composition. Consequently small pieces of plastic film end up in the bars.

In an alternative method of forming blocks the as-manufactured hot liquid cleansing composition is poured into moulds, and allowed to cool. However this leads to a need for a demoulding process. The blocks may not demould easily and the demoulding is labour-intensive (or equipment-intensive, if the scale of the manufacturing operation justifies high technology handling). Moreover if the blocks are kept in the moulds until they are sold there is likely to be a large investment in moulds; the moulds are, in that scenario, being used as storage modules.

The existing operational methods associated with blocks are not optimal.

In accordance with a first aspect of the present invention there is provided a method of forming a block of a personal cleansing composition, the method comprising:

-   -   forming a receptacle from a collapsed blank, the receptacle         being resistant to the liquid form of the personal cleansing         composition; and     -   casting the personal cleansing composition in its liquid form         into the receptacle, in direct contact with it, and allowing the         cleansing composition to cool, and set;

wherein the receptacle is reconfigurable into the collapsed blank to free the block.

In accordance with a second aspect of the present invention there is provided a pack comprising a block of personal cleansing composition cast in a receptacle, wherein:

-   -   the personal cleansing composition is solid at an ambient         temperature and liquid at an elevated temperature;     -   the personal cleansing composition is in direct contact with the         receptacle;     -   the receptacle is resistant to the liquid form of the personal         cleansing composition; and     -   the receptacle is configurable into a collapsed form to free the         block.

The walls of the receptacle may be made of a material which is resistant to the liquid form of the personal cleansing composition. For example they may be formed of a plastics material.

In other embodiments the inner surfaces of the walls may be resistant to the liquid form of the cleansing composition, while the base material of the walls may not of itself be adequately resistant to the liquid form of the personal cleansing composition.

Suitably the inner surface of the receptacle has a barrier layer to provide resistance to the liquid form of the personal cleansing composition. Suitable for this purpose may be plastics materials, silicone materials and metallic materials. For example, such materials may be provided in the form of foils or films on the inner surfaces of the receptacle, or as liquid coatings which are allowed to dry; for example spray coatings.

Such preferentially-resistant inner surfaces are suitably applied when the product is in the form of the collapsed blank, or at an earlier stage of the manufacturing process, to a sheet material from which the blank will be formed.

A suitable base material for the receptacle is a fibrous board or carton material, for example corrugated fibre board having outer skins, with a corrugated web between them.

Certain embodiments of the invention employ a fibrous board or carton material having a metallic/plastics foil attached to one surface.

Suitably the receptacle is cuboid, having a base wall and four upstanding side walls which come together at the corners. Suitably there are no seams or gaps between the base wall and the side walls. Suitably the base wall and side walls are formed from one piece of a sheet product. Suitably the pack has a collapsed form in which the base wall and side walls are generally in one plane, and an erect form in which each side wall is raised to be at 90° relative to the base wall, so that they meet at their edges and form the receptacle.

Suitably the receptacle is shape-stable. Suitably the receptacle is sufficiently shape-stable that a stack of at least 8 receptacles, each with molten composition inside, may be formed; with each receptacle being undistorted.

Suitably means are provided for holding the side walls together to maintain the shape of the receptacle, even when filled with liquid cleansing composition. Such means may be comprised by the material of the receptacle and the way it forms, or may be provided by a further part or parts, for example a strap or elastic, extending around the outside of the receptacle, or a strap or band, for example a microhook-and-microeye bands, extending around each corner of the receptacle.

Suitably the liquid cleansing composition is cast into the receptacle such as to occupy at least 75% of the volume of the receptacle. Suitably there is at least 1 cm between the surface of the liquid cleansing composition and the top of the receptacle. This is in order to avoid the risk of spillage.

In embodiments of the invention the block weights at least 1 kg. In other embodiments of the invention the block weights at least 2 kg. In further embodiments of the invention the block weights at least 5 kg.

Typically the temperature of the personal cleansing composition in liquid form when it is cast into the box is in the range 50-90° C.

By ambient temperature herein we mean, typically, 20° C.

Suitably the receptacle is provided with a lid. The lid may have a top panel and a downwards skirt, and fits over and around the receptacle. Suitably the inner surfaces of the lid are resistant to the liquid personal cleansing composition. This may be achieved in any of the ways described above for the receptacle itself.

Once the liquid personal cleansing composition has been poured into the receptacle, and the lid put on, the receptacle may be transferred to a storage location, with the composition still molten. At the storage location the composition is allowed to cool, and solidifies. The receptacles may be stacked on other receptacles, and further receptacles may in turn be stacked on it.

When blocks of the personal cleansing composition are purchased they may be supplied in the receptacles, without any necessity for cleansing composition to be removed for transportation. To use the cleansing composition the purchaser may collapse the receptacle, into the form of the blank from which it was made. In doing so the sides of the receptacle are splayed out and are pulled away from the block. Thus the block is rendered accessible, and may be lifted away, re-melted, and formulated with additives, and moulded to form the final cleansing bars.

According to a third aspect of the invention there is provided a method of storing a block of a personal cleansing composition which has been made by the method of the first aspect, still in the receptacle in which it was formed.

According to a fourth aspect of the invention there is provided a method of conveying a block of a personal cleansing composition which has been made by the method of the first aspect, by transporting it to the place of use, still in the receptacle in which it was formed.

According to a fifth aspect of the invention there is provided a method of using a block of a personal cleansing composition which has been made by the method of the first aspect, wherein the recipient collapses the receptacle into the form of the blank from which it was made, thereby rendering the block accessible.

It is found that the walls of the receptacle may separate very cleanly from the block, without any residue of personal cleansing composition on them. The receptacle, now in the form of a blank, may be recycled or re-used. Flattened blanks may be stacked so that they can be transported efficiently, for recycling or return to the seller of the blocks, for re-forming into the receptacle shapes into which the personal cleansing composition can again be cast.

According to a sixth aspect of the invention there is provided a method of storing, conveying and using a block of a personal cleansing composition which has been made by the method of the first aspect, wherein during the stages of storing and conveying the block is still in the receptacle in which it was formed, and in the step of using the block it is rendered accessible by unwrapping the receptacle from around the block.

Suitably the cleansing composition is a salt of a fatty acid (i.e. a soap, as defined chemically). Suitably the fatty acid is plant-derived.

The invention will now be further described, by way of example, with reference to the accompanying drawings, in which:

FIG. 1 shows a lidded receptacle formed of a metal foil-faced cardboard box;

FIG. 2 shows the box of FIG. 1 with the lid shown removed and inverted;

FIG. 3 shows the blank which is used to form the box, and showing what will be the outer face of the box;

FIG. 4 shows the same blank upside down showing what will be the inner face of the box;

FIG. 5 shows the blank at the start of the box-forming operation, in a perspective view;

FIG. 6 shows the blank at a later stage of the box-forming operation, seen in the same perspective;

FIG. 7 is a view corresponding to FIG. 6, but in plan view;

FIG. 8 shows the constructed box;

FIG. 9 is a detail showing the end wall of the box;

FIG. 10 shows the box containing a cast block of “melt and pour” soap (as an example of a personal cleansing composition);

FIG. 11 shows a second embodiment, having an alternative blank; and

FIG. 12 shows the box formed from the blank of FIG. 11.

The pack of FIGS. 1 to 10 has an upwardly open box 2 and a lid 4. The box has a base wall 6, opposed end walls 8 and 10, and opposed side walls 12 and 14. Each wall 8, 10, 12 and 14 is joined to the base wall by a fold line. The base wall and the side walls form an upwardly open cuboid void. The lid has a rectangular main panel 16 and a downwardly depending skirt 18 around its periphery, such that it may be placed over the box with the skirt outside the side walls of the box.

The receptacle is formed of corrugated board material, comprising outer skins of card material on each side of a corrugated web. The flat blank which is to form the receptacle is shown in FIG. 3, in plan view. The visible side of the blank is unfinished. That is to say, it is as-manufactured board material. FIG. 4 shows the opposite face of the same blank. This is finished with a metallic foil material. This is a laminate of a metallised skin on a tough plastics film. The metallised skin faces outwards.

The blank has panels 8′, 10′, 12′, and 14′ which will form the walls 8, 10, 12 and 14. Between each pair of adjoining side panels is a fillet piece 20 with a diagonal fold line 22. Extending along each side of the panel and its adjoining fillets 20 is a narrow skirt 24. Extending from the free edge of each end panel 8′ and 10′ is flap 26, 28. Each flap is generally in the form of a shallow triangle, from which a retaining tab 30, 32 projects.

These panels, flaps, skirts and tabs are connected to neighbouring parts by fold lines in the board material. It is important to note that the metallic foil, which is shown indicatively in FIG. 4, is not pierced anywhere.

The formation of the erected cuboid receptacle, from the blank, will now be described, with reference to FIGS. 5-8.

As can be seen in FIG. 5, the side panels 12′, 14′ are raised from the plane of the base wall 6′. They will form the side walls 12, 14 in the erected box. The flaps 24 are folded downwards.

As shown in FIG. 6, the side panels are lifted higher, and the end panels 8′, 10′ are lifted. They will form the walls of the box. The corner fillets now project outwardly from the box shape.

As now shown in FIG. 7, those corner regions are turned towards, then against, the respective end wall of the box, as indicated by the arrows. Once they are against the respective end walls of the box the corners of the box are tight. Moreover if liquid cleansing product should run between them it can only run into the region 36 in which there is face-to-face contact between fillet members of the corner regions; and even then, the corner region does not offer an exit path from the box.

When the corner regions are against the respective end wall of the box, the respective flap 26, 28 is laid over them, and the respective tab 30, 32 is pushed up between the respective end wall and the corner regions. The net effect is that a tight shape-stable box is formed, with little likelihood of liquid cleansing product escaping from the box. The under-surface of the flap/tab assembly functions as an aid to lifting the box.

Molten soap can now be poured into the box. To avoid spillage this is desirably up to a level 30 slightly below the rim 32 of the box. In this embodiment approximately 7 kg of soap is poured in. The box is perfectly stable against bursting. The soap can be allowed to set in the box. Once the soap has set, the box may be collapsed, by reversing the assembly sequence mentioned above. Once the end flaps are released the walls of the box can easily be pulled from the block. In tests we have undertaken we have invariably found that the block is a perfectly formed cuboid block, and that no soap has seeped through the corner seams.

The lid supplied for use with the box is of simple design and can be fitted over the box, containing the cleansing product, to keep it clean, and to facilitate stacking.

The box is constructed such that a stack of such boxes may be formed (for example at least eight boxes), each containing still-molten personal cleansing composition, without leakage from, or crushing of any boxes occurring.

The packs of cleansing blocks, within their boxes, may be stored in a warehouse until they are purchased. When purchased, the blocks, in their boxes, may be transported to the customer. When the customer requires them he “releases” the blocks from the boxes in the manner described. The blocks are naked and ready for use.

It will be appreciated that no flexible bag is used in the process described. The box functions as a pack for formation, storage and transportation of a block of personal cleansing composition. Removal of the block is easier than would be the case with a conventional one-piece mould, and if wished the blanks can be returned to the original location in a space-efficient, flattened, form, for re-use.

FIGS. 11 and 12 show an alternative embodiment. The blank of this alternative embodiment, shown in FIG. 11, comprises a base panel 106′, end panels 108′, 110′, and side panels 112′, 114′—and no further structure. Each panel 108′, 110′, 112′ and 114′ is joined to the base panel 106′, by a fold line. The panels are of a rigid plastics material which is resistant to a molten cleansing composition. The box is simply constructed by raising the side and end panels to form the walls 106, 108, 110, 112 and 114 and securing them in this position by microhook-and-microeye fastening means 120 (e.g. VELCRO®) around each corner, from one wall to the adjoining wall. There is a lid (not shown). The blank is made with sufficient accuracy that, when the fastening means are in place, liquid cleansing composition does not leak from the corners, even when several boxes (e.g. eight, or more), each containing still-liquid cleansing composition are set in a vertical stack. However if wished the lateral edges of the side walls, or of the end walls, or of both, of such a box may have applied to them a bead of a heat-resistant sealing material.

When the block is required to be re-melted, to make the end products, the cleansing bars, the fastening means are released and the side and end walls fall down or are folded down, to expose the block. 

1. A pack comprising a block of personal cleansing composition cast in a receptacle, wherein: the personal cleansing composition is solid at an ambient temperature and liquid at an elevated temperature; the personal cleansing composition is in direct contact with the receptacle; the receptacle is resistant to the liquid form of the personal cleansing composition; and the receptacle is configurable into a collapsed form to free the block.
 2. A pack as claimed in claim 1, wherein the walls of the receptacle may be made of a material which is resistant to the liquid form of the personal cleansing composition.
 3. A pack as claimed in claim 1, wherein the walls of the receptacle are formed of a base material and inner surfaces which are resistant to the liquid form of the cleansing composition.
 4. A pack as claimed in claim 3, wherein the inner surfaces have a barrier layer to provide resistance to the liquid form of the personal cleansing composition, wherein the barrier layer is provided in the form of foils or films on the inner surfaces of the receptacle, or as liquid coatings which have been allowed to dry.
 5. A pack as claimed in claim 4, wherein the barrier layer is selected from plastics materials, silicone materials and metallic materials.
 6. A pack as claimed in claim 3, wherein base material is a fibrous board material.
 7. A pack as claimed in claim 3, wherein the walls of the receptacle are of a fibrous board material having a metallic/plastics foil attached to one surface.
 8. A pack as claimed in claim 1, wherein the receptacle is cuboid, having a base wall and four upstanding side walls which come together at the corners, and formed from one piece of a sheet product.
 9. A pack as claimed in claim 8, wherein the receptacle has a collapsed form in which the base wall and side walls are generally in one plane, and an erect form in which each side wall is substantially orthogonal to the base wall, so that the side walls meet at their edges and form the receptacle.
 10. A pack as claimed in claim 1, wherein the block weighs at least 1 kg.
 11. A pack as claimed in claim 10, wherein the block weighs at least 5 kg.
 12. A pack as claimed in claim 1, wherein the cleansing composition is a salt of a plant-derived fatty acid.
 13. A method of forming a block of a personal cleansing composition, the method comprising: forming a receptacle from a collapsed blank, the receptacle being resistant to the liquid form of the personal cleansing composition; and casting the personal cleansing composition in its liquid form into the receptacle, in direct contact with it, and allowing the cleansing composition to cool, and set; wherein the receptacle is reconfigurable into the collapsed blank to free the block.
 14. A method of storing a block of a personal cleansing composition which has been made by the method of claim 13, still in the receptacle in which it was formed.
 15. A method of conveying a block of a personal cleansing composition which has been made by the method of claim 13, by transporting it to the place of use, still in the receptacle in which it was formed.
 16. A method of using a block of a personal cleansing composition which has been made by the method of claim 13, wherein the recipient collapses the receptacle into the form of the blank from which it was made, thereby rendering the block accessible.
 17. A method of storing, conveying and using a block of a personal cleansing composition which has been made by the method of claim 13, wherein during the stages of storing and conveying the block is still in the receptacle in which it was formed, and in the step of using the block it is rendered accessible by unwrapping the receptacle from around the block. 